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5894307-UIM-B-0920

Johnson Controls Ducted Systems

21

Ambient Combustion Air Supply

This  type  of  installation  draws  the  air  required  for  combustion  from
within  the  space  surrounding  the  appliance  and  from  areas  or  rooms
adjacent  to  the  space  surrounding  the  appliance.  This  can  be  from
within the space in a non-confined location or it can be brought into the
furnace area from outdoors through permanent openings or ducts. It is
not piped directly into the furnace. Provide a single, correctly sized pipe
from the furnace vent connector to the outdoors. It is best practice to
attach the supplied intake coupling and 18 in. of pipe to the furnace to
prevent accidental blockage of the combustion air intake.

An 

unconfined  space

  is  not  less  than  50  cu.  ft  (1.42  m

3

)  per  1,000

BTU/hr  (0.293  kW/h)  input  rating  for  all  of  the  appliances  installed  in
that area.
Rooms  communicating  directly  with  the  space  containing  the  appli-
ances  are  considered  part  of  the  unconfined  space,  if  doors  are  fur-
nished with openings or louvers.

confined  space

  is  an  area  with  less  than  50  cu.  ft  (1.42  m

3

)  per

1,000 BTU/hr (0.293 kW/h) input rating for all of the appliances installed
in that area. The following must be considered to obtain proper air for
combustion and ventilation in confined spaces.

Dampers, Louvers, and Grilles 

The blocking effects of louvers, grilles, and screens must be given con-
sideration in calculating free area. If the free area of a specific louver or
grille is not known, see Table 9 to estimate free area.

* Do not use less than 1/4 in. (6.4 mm) mesh.
+ Free area of louvers and grille varies widely. Follow the louver or grille manufac-

turer’s instructions.

• The free area of a supply air opening must be calculated by sub-

tracting  the  blockage  area  of  all  fixed  louvers  grilles  or  screens
from the gross area of the opening.

• Apertures in a fixed louver, grille, or screen must have no dimen-

sion smaller than 1/4 in. (6.4 mm).

• A manually operated damper or manually adjustable louvers are

not permitted for use.

• An  automatically  operated  damper  or  automatically  adjustable

louvers must be interlocked so the main burner can not operate
unless either the damper or the louver is in the fully open position.

 Figure 27: 

Combustion Airflow Path Through the Furnace Casing

 WARNING

This type of installation requires that the supply air to the appliance(s)
be of a sufficient amount to support all of the appliance(s) in the area.
Operation of a mechanical exhaust, such as an exhaust fan, kitchen
ventilation  system,  clothes  dryer  or  fireplace  may  create  conditions
requiring  special  attention  to  avoid  unsatisfactory  operation  of  gas
appliances. A venting problem or a lack of supply air will result in a
hazardous condition, which can cause the appliance to soot and gen-
erate dangerous levels of CARBON MONOXIDE, which can lead to
serious injury, property damage, and/or death.

COMBUSTION AIR

VENT PIPE 
CLAMPS INTO 
OUTLET OF
VENT COUPLING 
RAIN GUTTER

A1131-001

!

Table 9: 

Estimated Free Area

Wood or Metal

Louvers or Grilles

Wood 20–25%*

Metal 60–70% *

1/4 in. (6.4 mm)

mesh or larger 100%

 WARNING

When a Category I furnace is removed or replaced, the original vent-
ing  system  may  no  longer  be  correctly  sized  to  properly  vent  the
attached appliances.
An improperly sized vent system can cause CARBON MONOXIDE to
spill into the living space causing personal injury and/or death.

Table 10: 

Unconfined Space Minimum Area

BTUH Input Rating Minimum Free Area Required for Each Opening

60,000

60 in

2

 (387 cm

2

)

80,000

80 in

2

 (516 cm

2

)

100,000

100 in

2

 (645 cm

2

)

Table 11: 

Free Area

BTUH Input 

Rating

Minimum Free Area Required for Each Opening

Horizontal Duct 

(2,000 BTUH)

Vertical Duct or 

Opening to Outside 

(4,000 BTUH)

Round Duct

(4,000 BTUH)

60,000

30 in

2

 (193 cm

2

)

15 in

2

 (97 cm

2

)

5 in. (13 cm)

80,000

40 in

2

 (258 cm

2

)

20 in

2

 (129 cm

2

)

5 in. (13 cm)

100,000

50 in

2

 (322 cm

2

)

25 in

2

 (161 cm

2

)

6 in. (15 cm)

EXAMPLE: Determining Free Area.
Appliance 

1 Appliance 

2 Total Input

100,000  + 30,000 = (130,000 

 4,000) = 32.5 sq. in. vertical

Appliance 

1 Appliance 

2 Total Input

100,000  + 30,000 = (130,000 

 2,000) = 65 sq. in. horizontal

!

Summary of Contents for TL9E Series

Page 1: ...Wiring Diagram 32 LIST OF TABLES Unit Clearances to Combustibles 4 Cabinet and Duct Dimensions 6 Recommended Filter Sizes High Velocity 600 FPM 7 Ratings and Physical Electrical Data 8 Maximum Equival...

Page 2: ...alled directly on carpeting tile or other combustible material other than wood flooring Check the rating plate and power supply to be sure that the elec trical characteristics match All models use nom...

Page 3: ...t piping and elbows are required As centralized with the air distribution as possible Where adequate combustion air is available particularly when the appliance is not using outdoor combustion air Whe...

Page 4: ...be needed to ensure against drain pan distortion On all installations without a coil a removable access panel is recom mended in the outlet duct such that smoke or reflected light would be observable...

Page 5: ...ION This appliance is certified for line contact when the furnace is installed in the horizontal left or right position The line contact is only permissible between lines that are formed by the inters...

Page 6: ...t and quiet fur nace operation When suspending the furnace use a secure platform constructed of plywood or other building materials secured to the floor or ceiling joists See Figure 5 for details and...

Page 7: ...p leg and ground union is required See Figure 10 For left side supply gas pipe arrangement two 1 2 in elbows and two 1 2 in x 1 1 2 in pipe nipples must be used The arrangement shown in Figure 9 align...

Page 8: ...with DOE test procedures Wire size and overcurrent protection must comply with the National Electrical Code NFPA 70 latest edition and all local codes The furnace must be installed so the electrical...

Page 9: ...Figure 11 LOW VOLTAGE CONTROL WIRING CONNECTIONS Install the field supplied thermostat by following the instructions that come with the thermostat With the thermostat set in the OFF position and the m...

Page 10: ...1 67 LU RQGLWLRQHU 9ROW RPPRQ RPSUHVVRU RQWDFWRU XOO 6WDJH HDW 7 50267 7 Figure 13 Thermostat Chart Single Stage HP with Single Stage Furnaces 6LQJOH 6WDJH R1R XUQDFH 6LQJOH 6WDJH HDW 3XPS 6HFRQG 6WDJ...

Page 11: ...pplied to the hose con nected to the top of the condensate trap Screw the condensate trap to the condensate trap bracket supplied Then thread the hose adapters together below the furnace casing using...

Page 12: ...collec tor box as shown in Figures 16 and 17 The drain hose must not sag or droop after it is installed If glue is used when connecting the intake pipe to the intake coupling the drain opening in the...

Page 13: ...5894307 UIM B 0920 Johnson Controls Ducted Systems 13 Figure 16 Upflow Configuration UPFLOW LEFT SIDE DRAIN UPFLOW RIGHT SIDE DRAIN EXTERNAL CONDENSATE TRAP EXTERNAL CONDENSATE TRAP A1128 001...

Page 14: ...DRAIN AIRFLOW EXTERNAL CONDENSATE TRAP HORIZONTAL LEFT HORIZONTAL RIGHT MOVE RAIN GUTTER HOSE TO THIS POSITION MOVE CONDENSATE DRAIN HOSE TO THIS POSITION INTAKE PIPE DRAIN AIRFLOW EXTERNAL CONDENSAT...

Page 15: ...models are supplied with 2 in 5 1 cm vent connections When the pipe must be increased to 3 in 7 6 cm diameter the transition from 2 in to 3 in must be done as close to the furnace as possible The 2 i...

Page 16: ...igure 18 Elbow Dimensions A A A A STANDARD ELBOW LONG SWEEP ELBOW Table 6 Elbow Dimensions Elbow A Dimension Illustrated in Figure 18 2 in Standard 2 5 16 in 3 in Standard 3 1 16 in 2 in Sweep 3 1 4 i...

Page 17: ...nform to ASTM D2564 for PVC or ASTM D2235 for ABS piping 7 All joints must provide a permanent airtight and watertight seal 8 Install the combustion air and vent piping such that it has a 1 4 in ft 21...

Page 18: ...equirements of the gas supplier 12 in 30 5 cm or in accordance with local installation codes and the requirements of the gas supplier F Clearance to outside corner 12 in 30 5 cm or in accordance with...

Page 19: ...3 to 24 Each furnace must have a separate vent pipe Under NO circumstances can the two vent pipes be tied together The combustion air side of the two pipe configuration shown in Figures 23 and 24 can...

Page 20: ...tion See Figure 28 VENTILATED COMBUSTION AIR Combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in a ventilated att...

Page 21: ...operated damper or manually adjustable louvers are not permitted for use An automatically operated damper or automatically adjustable louvers must be interlocked so the main burner can not operate un...

Page 22: ...kW of the total input rating of all equipment located in the enclosure Not less than the sum of all vent connectors in the confined space The duct must be least the same cross sectional area as the fr...

Page 23: ...s dryers and TURN ON any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Open the fireplace dampers Do not operate a summer exhaust fan 4 Follow the light...

Page 24: ...surface igniter glows for about 17 s b After this warm up the induced draft blower starts again and the ignition module opens the main gas valve c After flame is established the supply air blower sta...

Page 25: ...0 300 750 78 46 92 231 25 144 288 720 80 45 90 225 26 138 277 692 82 44 88 220 27 133 267 667 84 43 86 214 28 129 257 643 86 42 84 209 29 124 248 621 88 41 82 205 30 120 240 600 90 40 80 200 31 116 23...

Page 26: ...ws on main gas valve 2 Turn on gas and electrical supplies and follow the operating instruc tions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw...

Page 27: ...gas sample for analysis it is permissi ble to drill a small hole in the plastic flue pipe for a sample probe pro vided that the vent piping is PVC and the hole is correctly sealed afterwards If using...

Page 28: ...ated on the furnace vesti bule panel near the gas valve This is an automatic reset control that provides over temperature protection due to reduced airflow This may be caused by the following A dirty...

Page 29: ...sensed within 1 0 s The gas valve de energizes and the control begins a recycle operation A normal ignition sequence begins after a 15 s inter purge If during the five recycles the gas supply does not...

Page 30: ...d Red Flashes Indicates incorrect line voltage polarity The polar ity of the incoming power to the furnace is reversed Soft Lockout The control includes a soft lockout that resets automati cally after...

Page 31: ...Door 1 5 ft required GROMMET 3 required HARNESS WIRING HOSE CONDENSATE HOSE RAIN GUTTER KNOB QUARTER TURN 4 required MOTOR MOUNT ORIFICE BURNER PAN CONDENSATE PLUG SEAL 7 8 in PLUG SEAL 2 3 8 in PLUG...

Page 32: ...5894307 UIM B 0920 32 Johnson Controls Ducted Systems SECTION XII WIRING DIAGRAM Figure 33 Wiring Diagram...

Page 33: ...ree Ells of 90 Degree Ells Polarity is correct black is L1 hot white is N neutral Ground wire is connected Line voltage value to furnace volts AC Low voltage value between R and C on furnace control b...

Page 34: ...ure in w c Return Static in w c after Air Side Heating Air Side Cooling Air Side Continuous Fan Clean Up Give owner the owner s manual provided Explain thermostat use and programming if applicable to...

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